Heating module for water heater

ABSTRACT

A heating module for a water heater includes a heater and a housing mounted to the heater. The heater includes a conductive pipe and a heating film attached to the outside of the conductive pipe. A room is defined between the housing and the heater for transferring heat to the water. The heating module is located in the tank of the water heater. When water enters into the tank, the conductive pipe transfers thermal energy to the water flowing through the conductive pipe by way of thermal convention. The water in the tank is heated by the housing by way of thermal conduction. The temperature of the water in the tank is quickly increased by the two ways.

BACKGROUND OF THE INVENTION 1. Fields of the Invention

The present invention relates to a water heater, and more particularly, to a heating module installed within the water heater so as to directly heat the water.

2. Descriptions of Related Art

The conventional water heater 10 is disclosed in FIG. 1 and comprises a tank 11 and a heater 12 which is connected to the outside of the tank 11. The reason that the heater 12 is connected to the outside of the tank 11 is to prevent the heater 12 from being in contact with water. The water enters into the heater 12 from the entrance 14 via a pump 13, and flows through the conductive pipe 15 which transfers thermal energy to the water so that the temperature of the water increases and then enters into the tank 11.

It is noted that the pump 13 is needed to move the water and the pump consumes electricity. When cold water enters into the tank 10, the temperature of the hot water in the tank 11 drops quickly, and therefore the heater 12 needs a longer period of time to keep the temperature. In the period, no hot water is provided to the users. Besides, the temperature of the water cannot be increased immediately. When the hot water in the tank 11 is not used for a period of time, the temperature drops, the tank 11 needs isolation material to reduce loss of the temperature of the water, or the heater 12 and the pump 13 have to work frequently.

The present invention intends to provide a heating module installed within the water heater so as to directly heat the water, the present invention eliminates the shortcomings mentioned above.

SUMMARY OF THE INVENTION

The present invention relates to a heating module for a water heater and comprises a heater having a conductive pipe and a heating unit, wherein the conductive pipe has a first entrance and a first exit. A path is connected between the first entrance and the first exit. The heating unit is connected to outside of the conductive pipe and includes a heating film attached to the outside of the conductive pipe. A first electrode and a second electrode are respectively located on the first end and the second end of the heating film.

A housing is mounted to outside of the heater. A room is defined between the housing and the heater. The housing has a second entrance and a second exit, wherein the second entrance is located corresponding to the first entrance, and the second exit is located corresponding to the first exit.

A seat is connected to the housing and the heater is connected to the seat. The seat has an introducing hole defined radially therethrough, and a convention hole and a wire hole are defined axially through the seat. The introducing hole is located corresponding to the first and second entrances. The convection hole is located corresponding to the room, and the wire hole allows wires of the heating unit to pass therethrough.

A seat board is connected to the lower end of the housing to seal an end of each of the conductive pipe, the seat and the housing. An installation unit is connected to the housing. The heating module is connected to the inside of the tank of the water heater by the installation unit. Multiple seal rings are located between the conductive pipe and the housing, between the conductive pipe and the seat, and between the housing and the seal board, and within the installation unit.

Preferably, a control unit is electrically connected to the heating unit and an inlet valve of the water heater. The heating unit is activated to run a water-heating mode when the control unit receives a water-in signal from the inlet valve of the water heater.

Preferably, a temperature sensor is located in the tank and electrically connected to the control unit. The heating unit is activated to switch the water-heating mode into a temperature-keeping mode when the control unit receives a signal from the temperature sensor.

Preferably, the heating module is installed close to an inlet pipe of the tank.

Preferably, the heating module is installed close to an outlet pipe of the tank.

Preferably, the outlet pipe of the tank extends through the conductive pipe.

Preferably, the second entrance of the housing includes at least one first hole defined in the wall of the housing. The at least one first hole is located corresponding to the introducing hole of the seat. The second exit of the housing includes at least one second hole, and the at least one second hole is located corresponding to the path of the conductive pipe.

The advantages of the present invention are that the heating film heats the conductive pipe to a desired temperature quickly. The housing is heated to the desired temperature as well by the conductive pipe via the room. The heating module is able to increase the desired temperature evenly and quickly.

When water enters into the tank, the conductive pipe transfers thermal energy to the water flowing through the conductive pipe by way of thermal convection. The water in the tank is heated by the housing by way of thermal conduction. The temperature of the water in the tank is quickly increased by the two ways.

The heating module runs a water-heating mode to quickly heat the water in the tank. The heating module runs a temperature-keeping mode to maintain the temperature of the water in the tank.

The heating unit is activated to switch temperature-keeping mode into the water-heating mode when the hot water is used and cold water enters into the tank, so that the temperature of the water in the tank does not drop dramatically. The heating module is installed close to the inlet pipe of the tank to heat the water in area close to the inlet pipe to prevent the temperature of the water in the tank does not drop dramatically.

The heating module is installed in the tank so that the conductive pipe and the housing are directly in contact with the water in the tank. The heating unit and the wires of the heating unit are separated from water.

The water heater using the heating module can quickly increase the temperature of the water in the tank, and the temperature can be maintained for a longer period of time to prevent the temperature of the water in the tank from dropping quickly. The users do not need to wait for the hot water.

The heating module can also be used to water drinking fountains.

The present invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, a preferred embodiment in accordance with the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a conventional water heater;

FIG. 2 is a cross sectional view of the heating module of the present invention;

FIG. 3 is a cross sectional view, taken along line III-III in FIG. 2;

FIG. 4 is a cross sectional view of the second embodiment of the heating module of the present invention;

FIG. 5 is a cross sectional view, taken along line V-V in FIG. 4;

FIG. 6 shows the operation of the heating module of the present invention disclosed in FIG. 2, and

FIG. 7 shows the operation of the heating module of the present invention disclosed in FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 2 and 3, the heating module 20 for a water heater 40 of the present invention comprises a heater 21 which includes a conductive pipe 22 and a heating unit 23, wherein the conductive pipe 22 has a first entrance 221 and a first exit 222. The conductive pipe 22 is made by heat isolation material such as ceramic and quartz. A path 223 is connected between the first entrance 221 and the first exit 222. The heating unit 23 is connected to outside of the conductive pipe 22 and includes a heating film 231 evenly attached to the outside of the conductive pipe 22. A first electrode 232 and a second electrode 233 are respectively located on the first end and the second end of the heating film 231. The first and second electrodes 232, 233 are respectively connected to the circuit and the power source (both not shown) to provide electricity to the heating film 231. The heating film 231 preferably is a semi-conductor heating film which increases the temperature of the conductive pipe 22 evenly and quickly.

A housing 30 is made of heat conductive material and mounted to outside of the heater 21. A room 31 is defined between the housing 30 and the heater 21. The housing 30 has a second entrance 32 and a second exit 33. The second entrance 32 of the housing 30 includes at least one first hole 321 defined in the wall of the housing 30. The at least one first hole 321 is located corresponding to the first entrance 221 of the conductive pipe 22. The second exit 33 of the housing 30 includes at least one second hole 331, and the at least one second hole 331 is located corresponding to the path 223 of the conductive pipe 22.

A seat 34 is connected to the housing 30 and the heater 21 is fixed to the housing 30 by the seat 34. Multiple seal rings 35 are located between the seat 34 and the heater 21 and the housing 30 to prevent water from entering the room 31 or leaking outward. The seat 34 has an introducing hole 341 defined radially therethrough, and a convention hole 342 and a wire hole 343 are defined axially through the seat 34. The introducing hole 341 is located corresponding to the second entrance 32 of the housing 30. The convection hole 342 is located corresponding to the room 31, and the wire hole 343 allows wires of the heating unit 23 to pass therethrough.

A seat board 50 is connected to the outside of the seat 34 and the lower end of the housing 30 to seal one end of each of the conductive pipe 22, the seat 34 and the housing 30.

An installation unit 60 is connected to the housing 30. The heating module 20 is connected to the inside of the tank 41 of the water heater 40 by the installation unit 60. The housing 30 is also installed to the inside of the tank 41 and located close to the inlet valve 421 of the tank 41.

FIGS. 2 and 3 show that the heater 21 includes one conductive pipe 22, and the FIGS. 4 and 5 show that the heater 21 includes multiple conductive pipes 22. The conductive pipes 22 are fixed to the housing 30 by the seat 34. There is a room 31 is defined between the each conductive pipe 22 and the housing 30. Multiple introducing holes 341 are defined radially through the wall of the seat 34 and each introducing hole 341 is located corresponding to the first and second entrances 221, 32, so as to introduce water into the conductive pipes 22. There are multiple second holes 331 defined in the wall that the second exit 33 is defined, and each second hole 331 is located corresponding the to the path 223 of the each conductive pipe 22.

As shown in FIG. 6, the heating module 20 is connected to the inside of the tank 41 of water heater 40 by the installation unit 60. The tank 41 includes the inlet pipe 42 for introducing water into the tank 41, the inlet valve 421 for controlling the inlet pipe 42, the outlet pipe 43 for being connected with pipes outside of the tank 41, the outlet valve 431 for controlling the outlet pipe 43, the temperature sensor 44 for detecting the temperature of the water in the tank 41, the level sensor 45 for detecting the water level of the tank 41, and the control unit 46 which is located at the outside of the tank 41 and electrically connected to the heating unit 23 and the inlet valve 421. The control unit 46 is connected to an outside power source (not shown) by a cable to provide electricity to the heating unit 23, the inlet valve 421, the temperature sensor 44, and the level sensor 45. The control unit 46 further has a control panel (not shown) to set the desired temperature that the heating unit 23 heats the water and the desired temperature of the water in the tank 41.

When the tank 41 is empty, the level sensor 45 sends a signal to the control unit 46 which opens the inlet valve 421 and activates the heating unit 23 to make the heating film 231 generates heat to quickly make the conduct pipe 22 have the desired temperature. The thermal energy of the heating film 231 is transferred to the housing 30 via the room 31, so that the housing 30 reaches the desired temperature. At this moment, the heating module 20 is at water-heating mode. The pressure of the water entering the tank 41 pushes the water in the tank 41 to pass the first hole 321 and the introducing hole 341 and enter into the path 223 of the conductive pipe 22. The rest of the water directly enters into the tank 41 and passes through the path 223 and enters into the tank 41 via the first exit 222 and the second hole 331. During the process of introducing water into the tank 41, the water in the tank 41 circulates via the above mentioned route. The conductive pipe 22 heats the water that circulates, and the water that does not enters into the conductive pipe 22 is heated by the housing 30. The conductive pipe 22 transfers thermal energy to the water flowing through the conductive pipe 22 by way of thermal convection. The water in the tank 41 is heated by the housing 30 by way of thermal conduction. The temperature of the water in the tank 41 is quickly increased by the two ways.

When the tank 41 is full, the level sensor 45 sends a signal to the control unit 45 which shuts off the inlet valve 421. The temperature sensor 44 detects the temperature of the water in the tank 41 reaches the desired temperature, the temperature sensor 44 sends a signal to the control unit 46 which then reduces the temperature of the heating module 20 and switches the water-heating mode into a temperature-keeping mode.

When the outlet valve 431 is opened, the water is released from the outlet pipe 43, and when the water level in the tank 41 is lowered to a certain height, the level sensor 45 sends a signal to the control unit 46 to open the inlet valve 421, and the temperature-keeping mode is switched into the water-heating mode. When the water source introduces water into the tank 41, the heating module 20 heats up the water in the tank 41 by the thermal convection and thermal conduction.

When the inlet valve 421 is opened, the outside water flows into the tank 41, the heating module 20 is immediately activated to proceed the water-heating mode to heat up the water so that the temperature of the water in the tank 41 does not drop quickly when the outside water enters into the tank 41. The heating module 20 is located close to the inlet pipe 42 so that the water at the inlet pipe 42 is first heated to prevent the water in the tank 41 from dropping quickly.

The heating module 20 is installed in the tank 41 so that the conductive pipe 22 and the housing 30 are directly in contact with the water in the tank 41. The heating unit 23 and the wires of the heating unit 23 are separated from water.

The water heater 10 using the heating module 20 can quickly increase the temperature of the water in the tank 41, and the temperature can be maintained for a longer period of time to prevent the temperature of the water in the tank 41 from dropping quickly. The users do not need to wait for the hot water. Also, the structure of the tank 41 makes the use of the isolation material to be minimized.

FIG. 7 shows the second embodiment, wherein the outlet pipe 43 extends through the conductive pipe 22 so that the water in the outlet pipe 43 is heated again by the conductive pipe 22. It is noted that the heating module 20 can also be used to water drinking fountains.

While we have shown and described the embodiment in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. 

What is claimed is:
 1. A heating module for a water heater, comprising: a heater having a conductive pipe and a heating unit, the conductive pipe having a first entrance and a first exit, a path connected between the first entrance and the first exit, the heating unit connected to outside of the conductive pipe and including a heating film attached to the outside of the conductive pipe, a first electrode and a second electrode respectively located on a first end and a second end of the heating film; a housing mounted to outside of the heater, a room defined between the housing and the heater, the housing having a second entrance and a second exit, the second entrance located corresponding to the first entrance, the second exit located corresponding to the first exit; a seat connected to the housing and the heater connected to the seat, the seat having an introducing hole defined radially therethrough, a convention hole and a wire hole defined axially through the seat, the introducing hole located corresponding to the first and second entrances, the convection hole located corresponding to the room, and the wire hole adapted to allow wires of the heating unit to pass therethrough; a seat board connected to a lower end of the housing to seal an end of each of the conductive pipe, the seat and the housing; an installation unit connected to the housing, the heating module connected to an inside of a tank of the water heater by the installation unit, and multiple seal rings located between the conductive pipe and the housing, between the conductive pipe and the seat, and between the housing and the seal board, and within the installation unit.
 2. The heating module for a water heater as claimed in claim 1, wherein a control unit is electrically connected to the heating unit and an inlet valve of the water heater, the heating unit is activated to run a water-heating mode when the control unit receives a water-in signal from the inlet valve of the water heater.
 3. The heating module for a water heater as claimed in claim 2, wherein a temperature sensor is located in the tank and electrically connected to the control unit, the heating unit is activated to switch the water-heating mode into a temperature-keeping mode when the control unit receives a signal from the temperature sensor.
 4. The heating module for a water heater as claimed in claim 1, wherein the heating module is installed close to an inlet pipe of the tank.
 5. The heating module for a water heater as claimed in claim 4, wherein the heating module is installed close to an outlet pipe of the tank.
 6. The heating module for a water heater as claimed in claim 5, wherein the outlet pipe of the tank extends through the conductive pipe.
 7. The heating module for a water heater as claimed in claim 1, wherein the second entrance of the housing includes at least one first hole defined in a wall of the housing, the at least one first hole is located corresponding to the introducing hole of the seat, the second exit of the housing includes at least one second hole, the at least one second hole is located corresponding to the path of the conductive pipe. 